3D-Printed Beam-Shaping Optics Using a Diffuse Conical Reflector

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Solution Overview

Problem

Reflective optical components used for beam shaping cannot be manufactured using additive manufacturing technology due to the need for highly reflective aluminum coverage, limiting their manufacturing methods and capabilities.

Innovation Solution

A conical reflector with a diffusely reflective inner surface and a transparent refractive hollow dome-shaped member, manufactured using fused deposition modeling (FDM) with a transparent polymeric material, to provide improved beam shaping and intensity gain, particularly in the forward direction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If highly reflective aluminium coverage is used on flat surfaces, then beam shaping capability is improved, but manufacturing complexity and cost increase due to inability to use additive manufacturing

Engineering Contradiction:

Improvebeam shaping capabilityVSAvoidmanufacturing capability

Core Design Contradiction:

Illumination intensityVSEase of manufacture

Solution Approach 1:

The patent replaces expensive, complex aluminum reflective coatings with a disposable, additive-manufactured polymeric reflector that achieves the same optical function through geometric design rather than material properties, enabling cost-effective manufacturing

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the fundamental parameter of reflection from material-based (aluminum coating) to geometry-based (3D printed surface structure), allowing the use of additive manufacturing technology while maintaining beam shaping capability

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If additive manufacturing is used to manufacture optical components, then manufacturing cost and ease of production are improved, but traditional high-reflectivity aluminum coating cannot be applied

Engineering Contradiction:

Improvemanufacturing costVSAvoidreflective performance

Core Design Contradiction:

Ease of manufactureVSIllumination intensity

Solution Approach 1:

The patent substitutes the mechanical/chemical process of aluminum coating deposition with an additive manufacturing process that builds the reflective surface geometry layer by layer, replacing traditional manufacturing methods with 3D printing technology

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses polymeric materials with integrated reflective geometric structures created through additive manufacturing, combining the advantages of plastic manufacturing ease with optical reflection functionality in a single composite structure

Inventive Principle:

Principle #40Composite materials

3Illumination intensity

If a transparent refractive hollow dome-shaped member is added to the optical component, then intensity gain in forward direction is improved, but device complexity increases

Engineering Contradiction:

Improveintensity gainVSAvoidstructural complexity

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The patent merges the dome-shaped refractive element with the conical reflector structure, integrating multiple optical functions (reflection and refraction) into a unified component that reduces overall device complexity while enhancing intensity gain

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs curved, dome-shaped geometry to refract and focus light in the forward direction, using spherical optics principles to achieve intensity gain without requiring complex multi-element optical systems

Inventive Principle:

Principle #14Spheroidality (Curvature)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution enables cost-effective manufacturing of optical components with enhanced beam shaping and intensity gain, utilizing a ribbed surface texture and layer-by-layer structure for optimized light distribution and intensity enhancement.

Implementation Method 1

a transparent refractive hollow dome-shaped member (102), wherein said transparent refractive hollow dome-shaped member has a proximal end arranged in contact with said conical reflector (101)

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 2

a conical reflector (101) having an inner surface being diffusely reflective

Methodology Applied

Scientific EffectDiffuse reflection: Reflection

Data Source

PatentUS20250383063A1Optical component, luminaire comprising such a component and manufacturing method therefor

Publication Date: 2025.12.18 SIGNIFY HOLDING BV

AI summary

The present invention relates to an optical component (100) for beam shaping comprising a conical reflector (101) having an inner surface being diffusely reflective, a transparent refractive hollow dome-shaped member (102), wherein said transparent refractive hollow dome-shaped member (102) has a proximal end (103) arranged in contact with said conical reflector (101), and a top (104) arranged at a distance from said conical reflector (101), wherein said top (104) has an opening (105) and that said transparent refractive hollow dome-shaped member (102) is manufactured by means of fused deposition modeling (FDM) using a transparent thermoplastic polymer material as printing material. The present invention also relates to a luminaire (10) and a method (200) for manufacturing such an optical component (100).